Large scale production of photovoltaic cells and resulting power

ABSTRACT

The present application discloses systems and methods for manufacturing large PV sheets and conveying large PV sheets away from the PV manufacturing site while routing power from the PV sheet to the grid.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/687,875, filed on Aug. 28, 2017 and entitled Large-ScaleProduction of Photovoltaic Cells and Resulting Power, now U.S. Pat. No.10,651,329, which is a continuation-in-part of U.S. patent applicationSer. No. 14/215,747, filed on Mar. 17, 2014, and entitled Large-ScaleProduction of Photovoltaic Cells and Resulting Power, now U.S. Pat. No.9,748,431, which claims priority to, and any other benefit of, U.S.Provisional Patent Application Ser. No. 61/794,688, filed on Mar. 15,2013, and entitled Large-Scale Production of Photovoltaic Cells andResulting Power (“the '688 Application”), which applications are herebyincorporated by reference in their entireties.

TECHNICAL FIELD

This invention relates to the production of photovoltaic cells and theirproduction on a large scale utilizing 3D printing techniques wherelayers of chemical compounds, lengths of conductive materials or othersuch manufacturing techniques are applied to a continuous ribbon ofdurable substrate material to produce a many miles long continuous arrayof solar cells that potentiate a photovoltaic reaction when exposed tosunlight AND the subsequent “In-Situ” generation of large-scaleelectrical power for distribution to the regional electrical grid systemfor utilization by residential, commercial or other end-users.

BACKGROUND

The conventional manufacturing of photovoltaic solar cells for theproduction of electricity results in a thick, heavy combination ofsilicon, glass, metal and plastic that are called solar panels or solarcells. These solar panels often need some type of metal or concretestand or framework to hold them at an optimum angle to the Sun's lightradiation. Needing to be produced in polluting large factories with“clean-rooms”, vast labor forces, extensive tooling and equipment,conventional solar panels cannot be produced on a large-scale in aneconomic or efficient manner. Moreover, the transportation, installationand deployment of such conventional solar panels at the location of thefinal end-user is expensive and time consuming yet yields comparativelylittle in added solar power capacity that might actually have asignificant impact upon our reliance on fossil fuels to generate thebulk of our electrical energy needs. In fact, to replace all theelectricity generated by fossil fuels in the United States alone(approximately 2,644 TWH), over 500 sq. miles of the most efficientsolar panels in production today would be required. This equates to morethan 1.3 Billion separate, individual, one-meter square conventionalsolar panels. Each panel requiring costly, environmentally degrading andtime-consuming manufacturing, transportation and installation processes.Obviously, to even approach the surface area of photovoltaic cells thatwould actually bring us an appreciable benefit, significant improvementsare needed on all fronts—manufacturing, transportation and deployment.The embodiments described herein bring all these needed improvements tobear in one environmentally sound, cost effective, high-capacity,high-speed, scalable, modular, upgradable and efficient design.

Photographs of the large factories, labor forces and complicated,expensive manufacturing processes that are required in conventionalsolar cell production standards are shown herein as FIG. 9.

Photographs of comparatively small-scale and expensive deployments ofconventional solar panel technology standards in “fields” or “farms”with concrete stands and steel framework are shown herein as FIG. 10 onpage 1 of the document “Concept for a Modular Photovoltaic Printer”,which is attached as Appendix 1 to the '688 Application, which isincorporated herein by reference in its entirety.

SUMMARY

Recently, Thin-Film PhotoVoltaic Solar Cell Technology (“TFSC”) has beendeveloped. This Thin-Film technology results in a thin photovoltaic cellthat can be and can effectively be printed on a thin, flexible substratelike plastic, laminate, composite, fabric or other such material inmultiple layers as narrow as 1-10 microns thick. The embodiments of thisinvention provide for the delivery of these Thin-Film PrintedPhotoVoltaic Solar Cells on a Large-Scale with In-Situ High-OutputElectrical Power Generation.

The structural embodiment of Large-Scale Production of PhotovoltaicCells and Resulting Power (“LSPPVRP”) which utilizes TFSC technology isan exemplary Integrated Large-Scale TFSC Production and Power GeneratingStation (“PVPPGS”) structure that has an approximate width of 150 feet,depth of 60 feet and height of 30 feet in this exemplary embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a Front/Right illustrated view of an exemplary IntegratedLarge-Scale Photovoltaic Printing and Power Generating Station(“PVPPGS”) structure that has an approximate width of 150 feet, depth of60 feet and height of 30 feet.

FIG. 2 is a Rear/Right illustrated view of an exemplary IntegratedLarge-Scale Photovoltaic Printing and Power Generating Station(“PVPPGS”) structure that has an approximate width of 150 feet, depth of60 feet and height of 30 feet.

FIG. 3 is a Top/Rear/Right illustrated view of a plurality of exemplaryIntegrated Large-Scale Photovoltaic Printing and Power GeneratingStation (“PVPPGS”) structures positioned proximate one another that eachhave an approximate width of 150 feet, depth of 60 feet and height of 30feet.

FIG. 4 is a Top, Landscape illustrated view of a plurality of exemplarydownrange PV Outputs emanating from a plurality of unseen PVPPGSstructures and how such would appear on the general landscape.

FIGS. 5A-5K together show an exemplary embodiment of the printed PVsheets shown schematically. These figures connect end-to-end vertically.Thirty-Six (36) small, discrete, individual solar cells make up aprogressively larger SP2 subpanel. Thirty-Six (36) individual SP2 solarpanels make up a progressively larger SP3 subpanel. Thirty-Six (36)individual SP3 solar panels make up a progressively larger SP4 subpanel.In some exemplary embodiments, each SP4 subpanel connects through a mainpositive and negative conductor to the main electrical grid.

FIGS. 6A and 6B are a chart and graphical representation, respectively,of exemplary downrange power outputs of the Integrated Large-ScalePhotovoltaic Printing and Power Generating Station (“PVPPGS”) in the“Tent” Configuration by time of day.

FIGS. 7A and 7B are a chart and graphical representation, respectively,of exemplary downrange power outputs of the Integrated Large-ScalePhotovoltaic Printing and Power Generating Station (“PVPPGS”) in the“Shower Curtain” Configuration by time of day.

FIG. 8 is a top illustrated view of exemplary downrange half-life“turn-around” of the PV Output for refurbishment and/or recycling afterthe useful life of the solar panels has been reached.

FIG. 9 shows exemplary illustrations of large factories, labor forcesand complicated, expensive manufacturing processes that are required inconventional solar cell production standards.

FIG. 10 shows exemplary illustrations of comparatively small-scale andexpensive deployments of conventional solar panel technology standardsin “fields” or “farms” with concrete stands and steel framework.

PRIOR ART

This section presents exemplary types of solar cells that can be used inthe inventive systems, methods, and solar cells discussed herein.

One exemplary type of Thin-Film Solar Cell as described in Appendix 2 tothe '688 Application, which is incorporated herein by reference in itsentirety, has six layers on a durable substrate material. The six layersare a back contact comprised of a conductive polymer, a P-typeSemiconductor Material, an N-type semiconductor material, a frontcontact which is again a conductive polymer, a protective coating and ananti-reflective coating. In exemplary embodiments of the presentinvention, six print heads would be used, one for each material appliedin succession on the substrate.

Other exemplary printable Thin-Film Solar Cells are described in theAppendices to the '688 Application, which is incorporated herein byreference in its entirety. An additional exemplary printable Thin-FilmSolar Cell is described in the following, which is incorporated hereinby reference in its entirety:

-   -   Plexcore® PV Inks for Printed Solar Power    -   http://www.sigmaaldrich.com/technical-documents/articles/technology-spotlights/plexcore-pv-ink-system.html.

Exemplary Thin-Film Solar Cell printers for printing PV sheets and PVribbons used herein are described in the following, which areincorporated herein by reference in their entireties:

-   -   http://oilprice.com/Latest-Energy-News/World-News/New-Machine-can-Print-PV-Solar-Cells-at-a-Rate-of-10-Metres-a-Minute        html;    -   http://www.kcet.org/news/rewire/solar/photovoltaic-pv/need-more-solar-cells-well-run-off-a-few-hundred-for-ya-mate.html.

DESCRIPTION

This Detailed Description merely describes exemplary embodiments of theinvention and is not intended to limit the scope of the claims in anyway. Indeed, the invention as claimed is broader than and unlimited bythe preferred embodiments, and the terms used in the claims have theirfull ordinary meaning, unless an express definition is provided herein.

Exemplary embodiments of the invention herein result in a “ribbon” ofcontinuous arrayed photovoltaic cells that extends many miles downrangeon a track system (either substantially horizontally or vertically) thatemanate from a large-scale, thin-film solar cell 3D printing structure,system and method with In-Situ high-output electrical power generationfor supply to the main power grid.

In FIG. 1, we see the front view of an exemplary Integrated Large-ScalePhotovoltaic Printing and Power Generating Station (“PVPPGS”) structurethat has an approximate width of 150 feet, depth of 60 feet and heightof 30 feet. The primary purpose of this PVPPGS structure is to house andcontain the mechanisms, components and equipment as required by theparticular process or method so utilized at that time for theLarge-Scale Production of Photovoltaic Cells and Resulting Power. Inthis exemplary embodiment, there are two separate Left and Right PVOutputs that are each 54 feet in width onto which the layers of chemicalcompounds, lengths of conductive materials or other such manufacturingtechniques have been applied to a continuous ribbon of durable substratematerial as required by the particular process or method so utilized atthat time in order for the completed production output to potentiate aphotovoltaic reaction when such is exposed to sunlight (“PV Output”).The PV Outputs (Left/Right) are produced within the PVPPGS structure bytwo distinct systems of multiple print heads, nozzles, sprayers, LEDs,lasers, applicators, fasteners, punches, cutters, presses and/or othersuch tooling and equipment (“Three-Dimensional Printing System” or“3DPS”) as required by the particular process or method so utilized atthat time.

In FIGS. 5A-5K, we can see that each of these individual componentdevices may be stationary or mobile along a track that covers the entirewidth of each sheet of substrate. The particular process, method ormanufacturing techniques to be used in production may be improved fromtime to time. As a result, the specific chemicals, compounds, ormaterials that is needed by the 3DPS can be changed, added or removed asnecessary. In addition, the specific print heads, nozzles, sprayers,LEDs, lasers, applicators, fasteners, punches, cutters, presses and/orother such tooling and equipment that is needed by the 3DPS can bechanged, added or removed as necessary. For instance, the use of ten(10) separate print heads, two “X” component modules, two (2) lasermodules and three (3) conductive wire applicators is only exemplary inthis illustration and there may be more or less than this number asrequired by the particular process or method so utilized at that time.

Within the PVPPGS structure, this substrate is routed in a “newsprint”fashion through a corresponding system of pullers, rollers andtensioners in order to maximize the separate surface areas or distinctplains available for simultaneous application of multiple chemicalcompounds, conductive materials or other such manufacturing techniques.In this exemplary embodiment, the interior of the PVPPGS structure alsocontains small control, office, maintenance, storage and break spacesfor a dedicated crew of 1-2 workers to successfully maintain proper PVcell production and control proper operational electrical current outputto the power grid. Additionally, there are many walkways, stairs, rampsand access points to the along with ample window, access and garagedoors to allow for a bright, safe and efficient work environment.

In FIG. 1, in front of and exiting the exemplary PVPPGS structure inthis front-view illustration, we see the two completed PV Outputs(Left/Right) that are each 54 feet in width that come together in alow-angled “Tent Configuration” that is approximately 100-feet wide. Insome exemplary embodiments, each side having been recently producedwithin the PVPPGS structure by the Three-Dimensional Printing Systemupon two separate continuous ribbons of durable substrate material.Although in this Illustration we see the PV Output extending downrangeonly a very short distance, the actual PV Output would continuedownrange many miles depending upon the total time the 3DPS systems hasbeen operational. Utilizing 2013 Thin-Film Solar Cells technology, it isprojected that each (Left/Right) 54-foot wide 3DPS system can produce acontinuous ribbon array of solar cells approximately three (3) mileslong per year and print 24 hours per day, 365 days per year. At thisrate in fifteen years, a forty-five (45) mile length of Thin-Film SolarCells would be produced. It is estimated that the printer would be a netuser of electricity from the power grid until the solar cell PV Outputis long enough such that it would become a net producer of electricity.It is estimated that this embodiment would become a net producer asopposed to a consumer of electricity in about 6 months.

In FIG. 1, in front of and exiting the PVPPGS structure in thisfront-view illustration, we also note the two Left and Right PV Outputsare routed upward on each inside edge in a low-angled “tent”configuration of 10-15 degrees (“Tent Configuration”) in order to 1)maximize whole-day sunlight exposure, 2) allow for drainage of rainwateraway from the PV Output, 3) allow for natural cleaning of dust, dirt anddroppings from the PV Output by rainwater and 4) allow the high-voltagecables to be elevated up and away from the ground along the “peak” ofthe two angled sections.

In FIG. 1, in front of the PVPPGS structure in this front-viewillustration, we also note the two Left and Right PV Outputs aresupported by a Downrange Trestle Support (“DTS”) structure that extendsaway from the PVPPGS structure and downrange for the entirety of thepath and length of the PV Output. The DTS structure would consist ofprefabricated triangular steel trestles affixed to ground buriedconcrete pilings approximately every 50-100 feet of longitudinal lengthand connected to each other by tubular steel girders. The PV Outputwould be pulled away from the PVPPGS structure by a system of gears,cogs, cables, pulleys and/or friction reduction devices attached to theDTS structure in various locations that is synchronized exactly with thethen-current longitudinal PV Output production speed. These DTScomponents would be added in a modular fashion on a regularly scheduledbasis in order to balance future production needs with currentoperational or fiscal limitations. In exemplary embodiments, the DTSstructure extend either directly South or directly North (orsubstantially South or Substantially North) away from theprinter/building, e.g., on an optimal route South (or North), takinginto account geography, property rights, environmental concerns, etc.This track would eventually extend miles (or many miles) out from theprinter building. In exemplary embodiments, the track system (either“shower curtain” or “lay flat”) is installed manually, as needed. Forexample, segments of track system can be added to the distal end as thedistal end of the printed PV sheet extends to that distal end of thetrack; one simply must be ahead of the printer so the printer can printcontinuously.

In FIG. 1, behind the PVPPGS structure in this front-view illustration,we note the high-voltage transmission lines and towers that connectdirectly to the main power grid. In some exemplary embodiments, each ofthe separate PVPPGS structures are thereby connected to the main powergrid by high-voltage cables that run the length of the PV output alongthe “peak” of the two angled PV Output sections. These PrimaryPower+/−(“PP+/−”) cables collect/return the entirety of the electricalenergy being produced by the photovoltaic cells along the length of theoutput. At the terminating point where the PV output first exits thePVPPGS structure, the PPC cables are routed laterally to two separatespools of reserve cable (positive and negative) and then routed up andrearwards until terminating and connecting to the high-voltagetransmission lines which are supported by the towers that are visible inthis illustration.

In FIG. 2, we see the rear view of an exemplary Integrated Large-ScaleTFSC Production and Power Generating Station (“PVPPGS”) structure thathas an approximate width of 150 feet, depth of 60 feet and height of 30feet.

In FIG. 2, behind the PVPPGS structure in this rear-view illustration,we note two (2) separate compartmented sections of the structure. Thesecompartments have an approximate width of 54 feet each, depth of 10 feetand height of 10 feet with a hinged and angled roof section that can beraised and lowed (“Substrate Roll Compartments” or “SRC”). TheseSubstrate Roll Compartments hold two (2) separate spools of durablesubstrate material (left/right). This substrate material would mostlikely be a woven carbon fiber fabric or other such similar durable,high-strength material that is wound upon a 54-foot-wide spool. In someexemplary embodiments, each spool would contain a length of substratethat would most likely be between 4,000 ft.-6,000 ft. Upon depletion ofthe two spools of substrate material, two new spools of substratematerial would be transported in by rail and/or truck. The depletedspools would be removed from the Substrate Roll Compartment and two newreplacement spools would be installed and permanently joined to thetail-end of previously depleted substrate sheet across the entire width.

In FIG. 2, behind the PVPPGS structure in this rear-view illustration,we also note four (4) high-tonnage jib cranes positioned above the two(2) separate compartmented sections of the structure containing thespools of substrate material. These jib cranes are used to facilitatethe removal of the depleted spools of substrate material and then toinstall the new replacement spools of substrate material which have beentransported immediately adjacent to the Substrate Roll Compartment byRail or Truck.

In FIG. 2, to the left of the PVPPGS structure in this rear-viewillustration we also note eight (8) liquid storage tanks that areconnected and routed into the PVPPGS structure through sections ofvalves and piping. These liquid storage tanks are used to store along-term reserve of each of the chemical compounds as required by theparticular process or method so utilized at that time to be applied tothe substrate material. Once pumped inside the PVPPGS structure from thestorage tanks the liquids would be routed to the specific 3DPS componentthat handles and applies to the substrate material that particularliquid through a network of pipes, valves, hoses, tanks, reservoirsand/or other such components. The necessary chemical compounds or ratiosthereof required by a particular process or method may be changed,eliminated or added through subsequent improvements of such. As aresult, these storage tanks may be used to store differing compounds orquantities as process or method improvements are developed.Additionally, the use of eight (8) separate tanks is only exemplary inthis illustration and there may be more or less than this number asrequired by the particular process or method so utilized at that time.

In FIG. 2, also to the left of the PVPPGS structure in this rear-viewillustration we note a tanker truck that is exemplary of the type thatmight be brought in on a set schedule in order to replenish the reserveof each of the chemical compounds as required by the particular processor method so utilized at that time.

In FIG. 3, we see the top view of an exemplary Integrated Large-ScaleTFSC Production and Power Generating Station (“PVPPGS”) structure thathas an approximate width of 150 feet, depth of 60 feet and height of 30feet.

In FIG. 3, we note in this top-view illustration that these PVPPGSstructures would be best located in geographical environments that havemany clear, cloudless days with bright sunshine over long hours of theday such as would be common in a low to mid latitude desert regions or,especially, “high desert” regions (desert regions at higher elevations).However, these PVPPGS structures could be built in any location thatenjoys sunshine—albeit with reduced efficiency and prolonged returns oninvestment.

In FIG. 3, we also note in this top-view illustration that these PVPPGSstructures would be best built in a grouping of one or more dozens ofstructures. This would offer beneficial economies of scale in landacquisition, construction, replenishment, maintenance and output powertransmission.

In FIG. 4, we see in this top-view, landscape illustration how a groupof downrange PV Outputs from a number of PVPPGS structures would appearon the general landscape.

In exemplary embodiments such as is shown schematically in FIGS. 5A-5K,the printed PV sheets consist of small discrete, individual subpanels ofthe size deemed most efficient for the particular process or method soutilized at that time by design factors such as efficiency,manufacturing processes, material properties, cost, etc. (e.g. 6″ sq.).As shown in these Illustrations, a number of these 3DPS manufacturedPV-1 cells (e.g. 36) would be, firstly, interconnected in seriesthrough, most likely, integrated printed circuits thereby creating aPV-2 subpanel. In some exemplary embodiments, each of these PV-2subpanels would be, secondly, interconnected in series through, mostlikely, conductive wire of appropriate gauge into PV-3 subpanels. Thisprocess would proceed until the width of the substrate material wasfully processed (i.e. about 54 feet). In some exemplary embodiments,each of these PV-3 subpanels would be, thirdly, interconnected in seriesthrough, most likely, conductive wire of larger appropriate gauge intoPV-4 subpanels. Certain subpanels are interconnected in series untiloptimal operational voltage is achieved. At this point, each PV-X+1Ysubpanels are then interconnected in parallel to achieve maximumobtainable operational current. Integrated printed circuits would beutilized (and would be preferable) until the design limitation of suchcircuits was reached and then outboard wiring of increasing conductorwire gauge size would become necessary. In essence, the lateral width ifthe completed PV Output is the primary factor in achieving operationalvoltage whereas the longitudinal length of the completed PV Output isthe primary factor in achieving maximum operational current output.Therefore, a PVPPGS system that has had time to produce two (2) miles ofPV Output would have nominal current of approximately 2× a PVPPGS systemthat has had time to produce only one (1) mile of PV Output. Both PVPPGSsystems, however, would operate at the same operational voltage, despitetheir respective length.

The exemplary embodiments of the invention in Illustrations 1A, 1B and1C all depict the PV Output in the downrange “Tent” Configuration. Thislow-angled, semi-horizontal embodiment would have maximum efficiency atastronomical noon or the time of day where the Sun is at its highestpoint. Exemplary Operational PV Current Output resulting from differingsunlight patterns at different times of the day of this particular“Tent” embodiment are depicted in FIGS. 6A and 6B.

In exemplary Tent Configuration embodiments, a low-cost, transparent,thin membrane may be suspended above the PV Output. When this layerbecomes dirt ridden, clouded or otherwise damaged by UV rays it can beeasily replaced in order to maintain optimal PV Output efficiency.

In other exemplary embodiments (e.g., FIG. 2 of U.S. Pat. No. 9,748,431)the PV Output is suspended substantially vertically from an elevated DTStrack system. This vertical embodiment has been called a “ShowerCurtain” embodiment because the Thin-Film Solar Cells would hangvertically from an elevated track like a shower curtain. In thisembodiment, the TFSC could be printed on both sides of the substratematerial or, just like in the Tent Configuration, can be printed on twoseparate substrate ribbons but then joined together back to back wheninstalled on the Vertical DTS System. In this embodiment, the lowestOperating Power Output would, surprisingly, occur at Astronomical Noonbecause the Sun would be directly overhead and shinning straight downupon the edge of the PV Output. In this design, the double-sided PVOutput is exposed to direct sunlight on one side half the day andexposed to indirect sunlight on the alternate side for the same period.At astronomical noon, both sides would be in indirect sunlight—albeitbathed in intense indirect light. After astronomical noon, the alternateside would now be in direct sunlight while the other side is now inindirect sunlight. This vertical embodiment may be preferable in somecircumstances over the Tent design because Operating Power Output wouldbe relatively consistent throughout the entire day from just aftersunrise to just before sunset. Therefore, contribution by the solarcells to the regional power grid would be more stable and of higherduration than the Tent Configuration. This vertical embodiment wouldalso be far less affected by sand, dirt, droppings, etc. ExemplaryOperational PV Current Output resulting from differing sunlight patternsat different times of the day of this particular “Shower Curtain”embodiment are depicted in FIGS. 7A and 7B.

In both horizontal and vertical exemplary embodiments, the PV printedfabric is outfitted with the necessary mounting hardware (depending onflat or shower curtain) after being printed and is then routed to theconveyor or support track for final mounting and routing.

In yet other exemplary embodiments, the substrate material may woven orotherwise manufactured at the site of the PVPPGS structure from carbonfiber yarn or other such material. This may ease any difficulties intransportation and handling of the large spools of substrate materialand reduce costs thereof.

In yet other exemplary embodiments, the PV Output (either “Tent” or“Shower Curtain” configuration) could be rerouted back to the PVPPGSstructure by routing the DTS structure in an “upside-down tear drop”shape (see FIG. 8). This rerouting would optimally occur exactly wherethe PV Output is then located downrange at the midway point (e.g. 10years) of its operational useful life (e.g. 20 years). Once back in thevicinity of the primary PVPPGS operations, the spent PV Output which hasexceeded its useful life and is no longer viable as a photovoltaicmedium, could possibly be refurbished and/or recycled. As improvementsin technology and methods occur that increase the operational usefullife of the PV Output, the midlife turnaround point can be moved furtherdownrange.

In all exemplary embodiments, automation of systems and processes isutilized to the greatest extent possible to minimize required laborinputs.

In exemplary embodiments, the following methodology used:

-   -   Connect the printer and building housing the printer to the        electrical grid;    -   The printer, track system, and associated circuits and        communications are powered by the electrical grid;    -   Continuously print PV sheet (as long as printing conditions are        met, e.g., all PV inks are available, grid power is available,        and there is sufficient buffer room in the building or        sufficient empty track to accept newly printed PV Output);    -   Continuously or intermittently convey printed PV Output to its        track (horizontal or vertical);    -   Route power from sun-exposed PV sheet to power the printer,        track system, and associated circuits and communications while        it is being generated;        -   While printing, and while the PV sheet provides insufficient            power (e.g., at night, or on cloudy days, or while the PV            sheet is relatively small), use grid power to power the            printer, track system, and associated circuits and            communications;        -   While not printing, e.g., when printing conditions are not            met, route power from sun-exposed PV sheet to the grid; and        -   While printing, and while the PV sheet provides sufficient            power, use PV sheet-generated power to power the printer,            track system, and associated circuits and communications and            route excess power to the grid.

Exemplary embodiments of the invention herein result in a “ribbon” ofcontinuous arrayed photovoltaic cells that extends many miles downrangeon a track system (either substantially horizontally or vertically) thatemanate from a large-scale, thin-film solar cell 3D printing structure,system and method with In-Situ high-output electrical power generationfor supply to the main power grid.

The embodiments described herein are only exemplary and not intended tolimit the scope or language of any future claims in any way which willhave all of their full ordinary meanings. While the present inventionhas been illustrated by the description of embodiments thereof, andwhile the embodiments have been described in considerable detail, it isnot the intention of the applicants to restrict or in any way limit thescope of the invention to such details. Additional advantages andmodifications will readily appear to those skilled in the art. Forexample, the track need not be a simple out and back configuration; asingle track can zig-zag back and forth away from the printer andoptionally back to the printer. As another example, although organic inkprinted PV substrates are discussed herein, the application is notlimited to organic ink PV printers or PV printers in general or even PVprinted substrates. Many benefits of the present application would beobtained by attaching traditional thin-film photovoltaic cells (e.g.,multijunction PV cells (2-terminal, monolithic), single-junction GAAs PVcells, crystalline Si PV cells, thin-film technology PV cells, and/orprinted PV cells) (with adhesive or fasteners or into transparent pocketin the substrate or other connection means) on a wide, flat andcontinuous substrate to form a wide, flat and continuous array of solarcells (also PV ribbons and PV sheets) using any of the related systemsand methods herein (e.g., horizontal track, vertical track, powermethods, powering the manufacturing site by the manufactured PV ribbonor PV sheet in sunlight, etc.). Traditional thin-film photovoltaic cells(e.g., multijunction PV cells (2-terminal, monolithic) can include, forexample, lattice matched, metamorphic, inverted metamorphic, threejunction (concentrator), three junction (non-concentrator), two junction(concentrator), two junction (non-concentrator), 4 or more junction(concentrator), or 4 or more junction (non-concentrator) PV cells.Single-junction GAAs PV cells can include, for example, single crystal,concentrator, or thin film crystal PV cells. Crystalline Si PV cells caninclude, for example, single crystal (concentrator), single crystal(non-concentrator), multicrystalline, thick Si film, siliconheterostructures (HIT), or thin-film crystal PV cells. Thin-filmtechnology PV cells can include, for example, CIGS (concentrator), CIGS,CdTe, Amorphous Si:H (stabilized), nani-Si, micro-Si, poly-Si, or multijunction polycrystalline PV cells. And printed PV cells can include, forexample, dye-sensitized cells, Perovskite cells, organic cells, organictandem cells, inorganic cells (e.g., CZTSSe), quatum dot cells, or anyof the other embodiments herein PV cells. In this broader context, theterms PV “ribbons” and PV sheets can mean any of these technologies andthe term PV printer throughout can be thought of as a manufacturingsite. As yet another example, the steps of all processes and methodsherein can be performed in any order, unless two or more steps areexpressly stated as being performed in a particular order, or certainsteps inherently require a particular order. Therefore, the inventiveconcept, in its broader aspects, is not limited to the specific details,the representative apparatus, and illustrative examples shown anddescribed. Accordingly, departures may be made from such details withoutdeparting from the spirit or scope of the applicant's general inventiveconcept.

What is claimed is:
 1. A solar power generation station comprising: asolar array extending from a first end to a second end; and a pluralityof interconnected solar cells extending from the first end to the secondend of the solar array; wherein the solar array is a wide, flat, andcontinuous array of the interconnected solar cells; and wherein thesolar array has a width of about 50 feet to about 200 feet and has acontinuous length of about 500 feet to about 20 miles.
 2. The solarpower generation station of claim 1, further comprising: a PV printerarranged at the first end of the solar array, wherein the PV printer isconfigured to print PV material to create new rows of interconnectedsolar cells at the first end of the solar array; and an automatedconveying system configured to convey the new rows of interconnectedsolar cells away from the PV printer and into a sun-lit area proximatethe PV printer, wherein the new rows of interconnected solar cells areattached to and extend the length of the solar array.
 3. The solar powergeneration station of claim 2, wherein the PV printer is configured toprint the PV material to form new rows of interconnected solar cellsusing large-scale 3D printing technology.
 4. The solar power generationstation of claim 2, wherein the automated conveying system is configuredto hang the solar array substantially vertically in the sun-lit area andis configured to permit the second end of the solar array to move awayfrom the PV printer as the new rows of interconnected solar cells areprinted by the PV printer at the first end of the solar array.
 5. Thesolar power generation station of claim 4, wherein the automatedconveying system is configured to turn about 180 degrees at a distal endto convey the second end of the solar array back to the PV printer whileremaining exposed to the sun in the sun-lit area.
 6. The solar powergeneration station of claim 2, wherein the automated conveying system isconfigured to support the solar array in a substantially horizontalorientation in the sun-lit area and is configured to permit the secondend of the solar array to move away from the PV printer as the new rowsof interconnected solar cells are printed by the PV printer at the firstend of the solar array.
 7. The solar power generation station of claim6, wherein the automated conveying system is configured to turn about180 degrees at a distal end to convey the second end of the solar arrayback to the PV printer while remaining exposed to the sun in the sun-litarea.
 8. The solar power generation station of claim 2, furthercomprising power transmission cables configured to route power generatedby the solar array to a power grid from a sun-exposed portion of thesolar array arranged in the sun-lit area proximate the PV printer. 9.The solar power generation station of claim 2, wherein the PV printer isconfigured to be powered exclusively by power generated from the solararray.
 10. The solar power generation station of claim 9, furthercomprising power transmission cables configured to route power generatedby the solar array in excess of the power needed to power the PV printeris routed to a power grid from a sun-exposed portion of the solar arrayarranged in the sun-lit area proximate the PV printer.
 11. A solar powergeneration station comprising: a solar array extending from a stationaryend to a moveable end; a plurality of rows of interconnected solar cellsextending from the stationary end to the moveable end of the solararray; a means of extending the solar array configured to add a new rowof solar cells to the plurality of rows of interconnected solar cells,wherein adding the new row of interconnected solar cells to theplurality of interconnected solar cells causes the movable end of thesolar array to move away from the stationary end of the solar array; anda means of conveying the plurality of rows of interconnected solar cellsconfigured to convey the plurality of rows of interconnected solar cellsaway from the means of extending the solar array and into a sun-litregion proximate the means of extending the solar array; wherein eachrow of the plurality of rows of interconnected solar cells has a widthof about 50 feet to about 200 feet.
 12. The solar power generationstation of claim 11, wherein the means of extending the solar array isconfigured to consume less power from a main power grid as each new rowof interconnected solar cells is added to the solar array.
 13. The solarpower generation station of claim 11, further comprising: a first row ofthe plurality of rows of interconnected solar cells, wherein the firstrow is arranged at the moveable end of the solar array; and an age gapbetween a first age of the first row of interconnected solar cells andsecond age of the new row of interconnected solar cells, wherein the agegap is at least 6 months.
 14. The solar power generation station ofclaim 13, wherein a power output generated by the solar power generationstation produces is greater than a power input needed to operate themeans of extending the solar array when the age gap is not more than 6months.
 15. The solar power generation station of claim 13, wherein themeans of conveying the solar array is configured to be turned about 180degrees when the age gap is about 10 years.
 16. The solar powergeneration station of claim 15, wherein the moveable end of the solararray is configured to return to the means of extending the solar arraywhen the age gap is about 20 years.
 17. The solar power generationstation of claim 13, wherein the first row of interconnected solar cellsis configured to be removed from the solar array when the age gap isabout 20 years.
 18. The solar power generation station of claim 11,wherein the means of conveying is configured to hang the solar arraysubstantially vertically in the sun-lit area and is configured to permitthe moveable end of the solar array to move away from the means ofextending the solar array as the new row of interconnected solar cellsis added to the stationary end of the solar array.
 19. The solar powergeneration station of claim 11, wherein the means of conveying isconfigured to support the solar array in a substantially horizontalorientation in the sun-lit area and is configured to permit the moveableend of the solar array to move away from the means of extending thesolar array as the new row of interconnected solar cells is added to thestationary end of the solar array.
 20. The solar power generationstation of claim 11, wherein the means of extending the solar array isconfigured to use large-scale 3D printing technology.